Semi-solid electrodes with gel polymer additive

ABSTRACT

Embodiments described herein relate generally to electrochemical cells having semi-solid electrodes that include a gel polymer additive such that the electrodes demonstrate longer cycle life while significantly retaining the electronic performance of the electrodes and the electrochemical cells formed therefrom. In some embodiments, a semi-solid electrode can include about 20% to about 75% by volume of an active material, about 0.5% to about 25% by volume of a conductive material, and about 20% to about 70% by volume of an electrolyte. The electrolyte further includes about 0.01% to about 1.5% by weight of a polymer additive. In some embodiments, the electrolyte can include about 0.1% to about 0.7% of the polymer additive.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to and benefit of U.S. ProvisionalPatent Application No. 61/856,188, filed Jul. 19, 2013, and entitled“Semi-Solid Electrodes with Gel Polymer Additives,” the disclosure ofwhich is incorporated by reference herein in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with government support under Grant NumberDE-AR0000102 awarded by the Department of Energy. The government hascertain rights in the invention.

BACKGROUND

Embodiments described herein relate generally to electrochemical cellshaving semi-solid electrodes that include a polymer additive such thatthe electrodes demonstrate better physical properties and longer cyclelife while significantly retaining the electronic performance of theelectrodes and the electrochemical cells formed therefrom.

Electrochemical cells or batteries are typically constructed of solidelectrodes, separators, electrolyte, and ancillary components such as,for example, packaging, thermal management, cell balancing,consolidation of electrical current carriers into terminals, and/orother such components. The electrodes typically include activematerials, conductive materials, binders and other additives.

Conventional methods for preparing electrochemical cells generallyinclude coating a metallic substrate (e.g., a current collector) withslurry composed of an active material, a conductive additive, and abinding agent dissolved or dispersed in a solvent, evaporating thesolvent, and calendering the dried solid matrix to a specifiedthickness. The electrodes are then cut, packaged with other components,infiltrated with electrolyte and the entire package is then sealed.

Such known methods generally involve complicated and expensivemanufacturing steps such as casting the electrode and are only suitablefor electrodes of limited thickness, for example, less than 100 μm(final single sided coated thickness). These known methods for producingelectrodes of limited thickness result in batteries with lower capacity,lower energy density and a high ratio of inactive components to activematerials. Furthermore, the binders used in known electrode formulationscan increase tortuosity and decrease the ionic conductivity of theelectrode.

Known electrochemical batteries such as, for example, lithium-ionbatteries also lose their charge capacity after repeated charge anddischarge cycles. Lithium-ion batteries are known to lose about 20% oftheir initial charge capacity after a year. This loss is attributed tomany factors including, for example, internal oxidation, exposure tohigh temperatures, alterations in crystal structure of componentsincluded in the anode and/or cathode, gas generation, and physical wearand tear. There is a need for new electrochemical batteries that do notlose charge capacity or do so at a much lower rate such that they havelonger cycle life.

Thus, it is an enduring goal of energy storage systems development todevelop new electrochemical batteries and electrodes that have longercycle life, increased energy density, charge capacity and overallperformance.

SUMMARY

Embodiments described herein relate generally to electrochemical cellshaving semi-solid electrodes that include a polymer additive such thatthe electrodes demonstrate better physical properties and longer cyclelife while significantly retaining the electronic performance of theelectrodes and the electrochemical cells formed therefrom. In someembodiments, a semi-solid electrode can include about 20% to about 75%by volume of an active material, about 0.5% to about 25% by volume of aconductive material, and about 20% to about 70% by volume of anelectrolyte. The electrolyte further includes about 0.1% to about 1.5%by weight of a polymer additive. In some embodiments, the electrolytecan include about 0.1% to about 1% of the polymer additive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an electrochemical cell, accordingto an embodiment.

FIG. 2 is a schematic flow diagram of a method for preparing asemi-solid electrode slurry, according to an embodiment.

FIG. 3 is a plot of charge capacity retained by electrochemical cellsthat include various quantities of gel polymer additive in a semi-solidanode and a semi-solid cathode after 12 charge and discharge cycles.

FIG. 4 is a plot of energy efficiency of the electrochemical cells ofFIG. 3 after 12 charge and discharge cycles.

FIG. 5 is a plot of area specific impedance of the electrochemical cellsof FIG. 3 after 12 charge and discharge cycles.

FIG. 6 is a plot of normalized charge capacity of variouselectrochemical cells at different charge rates after 10 charge cycles.

FIG. 7 is a plot of normalized discharge capacity of the electrochemicalcells at different discharge rates after 10 discharge cycles.

FIG. 8 is a plot of the stiffness of semi-solid cathodes included in theelectrochemical cells of FIG. 3 after mixing and after curing undervarious curing conditions.

FIG. 9 is a plot of the stiffness of semi-solid anodes included in theelectrochemical cells of FIG. 3 after mixing and after curing undervarious curing conditions.

FIG. 10 is a plot of voltage vs capacity of an electrochemical cell thatincludes a control semi-solid anode compared with the voltage vscapacity plot of three electrochemical cells that include semi-solidanodes having a CMC polymer, a Daiso polymer, or a Nippon Shokubaipolymer in the semi-solid anode formulation, at a C-rate of C/10.

FIG. 11 is a plot of voltage vs capacity of the electrochemical cells ofFIG. 10 at a C-rate of C/4.

FIG. 12 is a plot showing the capacity retained by the electrochemicalcells of FIG. 10 after 5 cycles.

DETAILED DESCRIPTION

Embodiments described herein relate generally to electrochemical cellshaving semi-solid electrodes that include a polymer additive such thatthe electrodes demonstrate better physical properties and longer cyclelife while significantly retaining the electronic performance of theelectrodes and the electrochemical cells formed therefrom.

Consumer electronic batteries have gradually increased in energy densitywith the progress of lithium-ion battery technology. The stored energyor charge capacity of a manufactured battery is a function of: (1) theinherent charge capacity of the active material (mAh/g), (2) the volumeof the electrodes (cm³) (i.e., the product of the electrode thickness,electrode area, and number of layers (stacks), and (3) the loading ofactive material in the electrode media (e.g., grams of active materialper cm³ of electrode media). Therefore, to enhance commercial appeal(e.g., increased energy density and decreased cost), it is generallydesirable to increase the areal charge capacity (mAh/cm²). The arealcharge capacity can be increased, for example, by utilizing activematerials that have a higher inherent charge capacity, increasingrelative percentage of active charge storing material (i.e., “loading”)in the overall electrode formulation, and/or increasing the relativepercentage of electrode material used in any given battery form factor.Said another way, increasing the ratio of active charge storingcomponents (e.g., the electrodes) to inactive components (e.g., theseparators and current collectors), increases the overall energy densityof the battery by eliminating or reducing components that are notcontributing to the overall performance of the battery. One way toaccomplish increasing the areal charge capacity, and therefore reducingthe relative percentage of inactive components, is by increasing thethickness of the electrodes.

Semi-solid electrodes described herein can be made: (i) thicker (e.g.,greater than 250 μm-up to 2,000 μm or even greater) due to the reducedtortuosity and higher electronic conductivity of the semi-solidelectrode, (ii) with higher loadings of active materials, and (iii) witha simplified manufacturing process utilizing less equipment. Thesesemi-solid electrodes can be formed in fixed or flowable configurationsand decrease the volume, mass and cost contributions of inactivecomponents with respect to active components, thereby enhancing thecommercial appeal of batteries made with the semi-solid electrodes. Insome embodiments, the semi-solid electrodes described herein arebinderless and/or do not use binders that are used in conventionalbattery manufacturing. Instead, the volume of the electrode normallyoccupied by binders in conventional electrodes, is now occupied by: 1)electrolyte, which has the effect of decreasing tortuosity andincreasing the total salt available for ion diffusion, therebycountering the salt depletion effects typical of thick conventionalelectrodes when used at high rate, 2) active material, which has theeffect of increasing the charge capacity of the battery, or 3)conductive additive, which has the effect of increasing the electronicconductivity of the electrode, thereby countering the high internalimpedance of thick conventional electrodes. The reduced tortuosity andhigher electronic conductivity of the semi-solid electrodes describedherein, results in superior rate capability and charge capacity ofelectrochemical cells formed from the semi-solid electrodes. Embodimentsof the semi-solid electrodes described herein can be used in anyelectrochemical cell such as, for example, a primary battery, asecondary battery, an electrodouble layer capacitor, a pseudocapacitor,or any other electrochemical cell or combination thereof.

Since the semi-solid electrodes described herein, can be madesubstantially thicker than conventional electrodes, the ratio of activematerials (i.e., the semi-solid cathode and/or anode) to inactivematerials (i.e. the current collector and separator) can be much higherin a battery formed from electrochemical cells that include thesemi-solid electrodes described herein relative to a similar batteryformed form electrochemical cells that include conventional electrodes.This substantially increases the overall charge capacity and energydensity of a battery that includes the semi-solid electrodes describedherein. Examples of electrochemical cells utilizing thick semi-solidelectrodes and various formulations thereof are described in U.S. PatentApplication Publication No. 2014/0170524 (also referred to as “the '524publication”), published Jun. 19, 2014, entitled “Semi-Solid ElectrodesHaving High Rate Capability,” and U.S. patent application Ser. No.14/202,606 (also referred to as “the '606 application), filed Mar. 15,2013, entitled “Asymmetric Battery Having a Semi-Solid Cathode and HighEnergy Density Anode,” the entire disclosures of which are herebyincorporated by reference.

Known electrochemical batteries such as, for example, lithium ionbatteries tend to lose their initial charge capacity after eachcharge/discharge cycle. For example, it is known that lithium batteriesused in devices, such as, for example, cell phones, laptops, cameras,etc. do not maintain the same charge capacity that was held by thelithium batteries when they were initially charged. Lithium batteriesare known to lose about 20% of their initial charge capacity after ayear of normal use. Without being bound by any particular theory, thisdecrease in charge capacity is attributed to, for example, (1) internalcell oxidation; (2) change in crystal structure of the cathode and/oranode; (3) thickening and/or breakdown of the solid electrolyteinterphase (SEI) layer formed by the non-aqueous electrolyte on theanode; (4) exposure to high temperatures such as, for example,temperatures above 100 degrees Fahrenheit, and; (5) physical wear andtear of the cathode, anode, and/or current collectors. In particular,the electrodes can expand and contract during charging and dischargingbecause of the intercalation of lithium ions into and out of theelectrodes which results in increased internal impedance and/orbreakdown of the anode SEI layer. Furthermore, gas generation due toknown electrochemical reactions in lithium batteries can also contributeto the ultimate wear and tear of the electrodes that can reduce thecharge capacity and hence cycle life of the electrodes.

Embodiments of semi-solid electrodes described herein include a smallquantity of a polymer additive, for example, a polymer or a gel polymerin the semi-solid electrode slurry composition. Gel polymers arecompositions that include a monomer such as, for example, an acrylate ormethacrylate based monomer dissolved in an appropriate solvent such as,for example, a non aqueous electrolyte. The monomer can be polymerizedsuch as, for example, physically cross linked or chemically cross linked(e.g., through temperature or UV curing), such that the gel polymersolidifies into a gel. The amount of solidification or “gellation” isdependent on the quantity of polymer dissolved in the solvent, forexample, a non-aqueous electrolyte. These gel polymers are used in someknown lithium electrochemical cells in place of the non-aqueous liquidelectrolyte. The central purpose of known gel polymers used inconventional electrochemical cells is to act as a solid phaseelectrolyte to provide mechanical integrity to the electrochemical celland reduce leakage that can happen with liquid electrolytes. Thequantity of polymer in the gel polymer additive included in thesemi-solid electrodes described herein is defined such that the gelpolymer additive does not lead to any significantgellation/solidification of the semi-solid slurry composition and alsoimproves physical and/or electronic properties of the semi-solid slurryelectrodes. Said another way, the gel polymer additive can improve therheological properties of the semi-solid slurry electrodes for example,by inhibiting migration of active and/or conductive particles duringcycling, without having any meaningful impact on the flowability of thesemi-solid slurry. Furthermore, the small quantity of the gel polymeradditive can enhance the cohesiveness of the semi-solid slurry such thatthe semi-solid slurry has a more stable and uniform viscosity andstiffness. This can improve the shape keeping ability of the semi-solidelectrodes and prevent separation of the semi-solid anode and/orcathode. Moreover, any other polymers can also be used in the semi-solidelectrodes described herein which can improve the rheological propertiesof the semi-solid electrode without having any meaningful impact on theelectronic properties of the semi-solid slurry. In some embodiments, thepolymer additive, for example, the gel polymer additive included in thesemi-solid electrode can be cured. In some embodiments, the polymeradditive included in the semi-solid electrode improves the rheologicalproperties of the semi-solid electrodes without being cured.

Semi-solid electrodes described herein provide several advantagesincluding; (1) longer cycle life, i.e. the charge capacity ofelectrochemical cells composed of the semi-solid electrodes describedherein is retained for a greater number of charge/discharge cycles; (2)a significant portion of the semi-solid electrode energy efficiency ismaintained; (3) area specific impedance (ASI) is lowered; (4) shapekeeping ability of the semi-solid electrode is improved; and (5)separation of the semi-solid electrode slurry materials is substantiallyreduced or eliminated. In some embodiments, when a single ion transfergel polymer additive is used, the semi-solid electrode polarization canbe lowered which can yield semi-solid electrodes with higher electronconductivity and charge capacity (Ryu, et al., “Rate performance isstrongly related to the electrode polarization by the limitation ofOhmic loss, energy transfer and mass transfer”, J. Echem. Soc. & Tech,Vol. 2, No. 3, pp. 136-142 (2011)). Furthermore, semi-solid electrodesdescribed herein can also have higher loading of ion-storing solid phasematerials (e.g., active materials and/or conductive materials).Therefore, semi-solid electrodes described herein can have a highercharge capacity and higher energy density when compared to semi-solidelectrodes that do not include a gel polymer additive.

In some embodiments, semi-solid electrodes described herein that includethe polymer additive, for example, a gel polymer additve or any otherpolymer additive described herein can have reduced stiffness. Thereduced stiffness can make it easier to manufacture static (i.e.,stationary) or flowable semi-solid electrodes, for example, by making iteasier to cast and/or flow the electrode composition. In particular,reduction in stiffness can also increase the flowability of semi-solidflowable electrodes which can reduce physical wear and tear of thesemi-solid electrodes and increase cycle life.

In some embodiment, a semi-solid electrode can include about 20% toabout 75% by volume of an active material, about 0.5% to about 25% byvolume of a conductive material, and about 20% to about 70% by volume ofan electrolyte. The electrolyte includes 0.01% to about 1.5% by weightof a polymer additive. In some embodiments, the electrolyte can includeabout 0.1% to about 1% by weight of the polymer additive.

In some embodiments, an energy storage device includes a positivecurrent collector, a negative current collector and an ion permeablemembrane disposed between the positive current collector and thenegative current collector. The ion permeable membrane is spaced fromthe positive current collector and at least partially defines a positiveelectroactive zone. The ion permeable membrane is also spaced from thenegative current collector and at least partially defines a negativeelectroactive zone. A semi-solid electrode is disposed in at least oneof the positive electroactive zone and the negative electroactive zone.The semi-solid electrode includes a suspension of an ion-storing solidphase material in a non-aqueous electrolyte which includes about 0.01%to about 1.5% by weight of a polymer additive. In some embodiments, thevolume percentage of the ion-storing solid phase material in thenon-aqueous electrolyte can be between about 20% to about 75%.

In some embodiments, a method for preparing a semi-solid electrodeincludes combining a polymer additive with a non-aqueous liquidelectrolyte to form a polymer-electrolyte mixture. An active material iscombined with the polymer-electrolyte mixture to form an intermediatematerial. A conductive additive is then added to the intermediatematerial to form a semi-solid electrode material. The semi-solidelectrode material is formed into an electrode. Optionally, the polymeradditive can be cured. In some embodiments, the concentration of thepolymer additive in the non-aqueous liquid electrolyte is in the rangeof about 0.01% to about 1.5% by weight.

In some embodiments, the electrode materials described herein can be aflowable semi-solid or condensed liquid composition. A flowablesemi-solid electrode can include a suspension of an electrochemicallyactive material (anodic or cathodic particles or particulates), andoptionally an electronically conductive material (e.g., carbon) in anon-aqueous liquid electrolyte. Said another way, the active electrodeparticles and conductive particles are co-suspended in an electrolyte toproduce a semi-solid electrode. Examples of battery architecturesutilizing semi-solid flowable electrodes are described in U.S. PatentApplication Publication No. 2011/0200848 (also referred to as “the '848publication”), published Aug. 8, 2011, entitled “High Energy DensityRedox Flow Device”, and U.S. Pat. No. 8,722,226 (also referred to as“the '226 patent”), issued Aug. 18, 2011, entitled “High Energy DensityRedox Flow Device”, the entire disclosures of which are incorporatedherein by reference in their entirety.

In some embodiments, semi-solid electrode compositions (also referred toherein as “semi-solid suspension” and/or “slurry”) described herein canbe mixed in a batch process e.g., with a batch mixer that can include,for example, a high shear mixture, a planetary mixture, a centrifugalplanetary mixture, a sigma mixture, a CAM mixture, and/or a rollermixture, with a specific spatial and/or temporal ordering of componentaddition. In some embodiments, slurry components can be mixed in acontinuous process (e.g. in an extruder), with a specific spatial and/ortemporal ordering of component addition.

The mixing and forming of a semi-solid electrode generally includes: (i)raw material conveyance and/or feeding, (ii) mixing, (iii) mixed slurryconveyance, (iv) dispensing and/or extruding, and (v) forming. In someembodiments, multiple steps in the process can be performed at the sametime and/or with the same piece of equipment. For example, the mixingand conveyance of the slurry can be performed at the same time with anextruder. Each step in the process can include one or more possibleembodiments. For example, each step in the process can be performedmanually or by any of a variety of process equipment. Each step can alsoinclude one or more sub-processes and, optionally, an inspection step tomonitor process quality.

In some embodiments, the process conditions can be selected to produce aprepared slurry having a mixing index of at least about 0.80, at leastabout 0.90, at least about 0.95, or at least about 0.975. In someembodiments, the process conditions can be selected to produce aprepared slurry having an electronic conductivity of at least about 10⁻⁶S/cm, at least about 10⁻⁵ S/cm, at least about 10⁻⁴ S/cm, at least about10⁻³ S/cm, or at least about 10⁻² S/cm. In some embodiments, the processconditions can be selected to produce a prepared slurry having anapparent viscosity at room temperature of less than about 100,000 Pa-s,less than about 10,000 Pa-s, or less than about 1,000 Pa-s, all at anapparent shear rate of 1,000 s⁻¹. In some embodiments, the processconditions can be selected to produce a prepared slurry having two ormore properties as described herein. Examples of systems and methodsthat can be used for preparing the semi-solid electrode compositionsdescribed herein are described in U.S. Patent Application PublicationNo. US 2013/0337319 (also referred to as “the '319 publication”),published Dec. 19, 2013, entitled “Electrochemical Slurry Compositionsand Methods for Preparing the Same,” the entire disclosure of which ishereby incorporated by reference.

As used herein, the term “about” and “approximately” generally mean plusor minus 10% of the value stated, e.g., about 250 μm would include 225μm to 275 μm, about 1,000 μm would include 900 μm to 1,100 μm.

As used herein, the term “semi-solid” refers to a material that is amixture of liquid and solid phases, for example, such as particlesuspension, colloidal suspension, emulsion, gel, or micelle.

As used herein, the terms “activated carbon network” and “networkedcarbon” relate to a general qualitative state of an electrode. Forexample, an electrode with an activated carbon network (or networkedcarbon) is such that the carbon particles within the electrode assume anindividual particle morphology and arrangement with respect to eachother that facilitates electrical contact and electrical conductivitybetween particles and through the thickness and length of the electrode.Conversely, the terms “unactivated carbon network” and “unnetworkedcarbon” relate to an electrode wherein the carbon particles either existas individual particle islands or multi-particle agglomerate islandsthat may not be sufficiently connected to provide adequate electricalconduction through the electrode.

FIG. 1 shows a schematic illustration of an electrochemical cell 100.The electrochemical cell 100 includes a positive current collector 110,a negative current collector 120 and a separator 130 disposed betweenthe positive current collector 110 and the negative current collector120. The positive current collector 110 is spaced from the separator 130by a first distance t₁ and at least partially defines a positiveelectroactive zone. The negative current collector 120 is spaced fromthe separator 130 by a second distance t₂ and at least partially definesa negative electroactive zone. A semi-solid cathode 140 is disposed inthe positive electroactive zone and an anode 150 (e.g., semi-solidanode) is disposed in the negative electroactive zone. In someembodiments, the thickness of the positive electroactive zone defined bythe distance t₁ and/or the thickness of the negative electroactive zonedefined by the distance t₂ can be in range of about 250 μm to about2,000 μm.

The semi-solid cathode 140 and/or anode 150 (e.g., semi-solid anode) canbe disposed on a current collector, for example, coated, casted, dropcoated, pressed, roll pressed, or deposited using any other suitablemethod. The semi-solid cathode 140 can be disposed on the positivecurrent collector 110 and the anode 150 can be disposed on the negativecurrent collector 120. For example the semi-solid cathode 140 and/oranode 150 (e.g., semi solid anode) can be coated, casted, calenderedand/or pressed on the positive current collector 110 and the negativecurrent collector 120, respectively. The positive current collector 110and the negative current collector 120 can be any current collectorsthat are electronically conductive and are electrochemically inactiveunder the operating conditions of the cell. Typical current collectorsfor lithium cells include copper, aluminum, or titanium for the negativecurrent collector 120 and aluminum for the positive current collector110, in the form of sheets or mesh, or any combination thereof. In someembodiments, the semi-solid cathode 140 and/or anode 150 can be aflowable semi-solid electrode for use in a redox flow cell such as, forexample, the semi-solid electrode compositions and redox flow cells thatare described in the '848 publication and the '226 patent.

Current collector materials can be selected to be stable at theoperating potentials of the semi-solid cathode 140 and anode 150 (e.g.,semi-solid anode) of the electrochemical cell 100. For example, innon-aqueous lithium systems, the positive current collector 110 caninclude aluminum, or aluminum coated with conductive material that doesnot electrochemically dissolve at operating potentials of 2.5-5.0V withrespect to Li/Li⁺. Such materials include platinum, gold, nickel,conductive metal oxides such as vanadium oxide, and carbon. The negativecurrent collector 120 can include copper or other metals that do notform alloys or intermetallic compounds with lithium, carbon, and/orcoatings comprising such materials disposed on another conductor.

The semi-solid cathode 140 and the anode 150 (e.g., semi-solid anode)included in an electrochemical cell can be separated by a separator 130.For example, the separator 130 can be any conventional membrane that iscapable of ion transport. In some embodiments, the separator 130 is aliquid impermeable membrane that permits the transport of ionstherethrough, namely a solid or gel ionic conductor. In some embodimentsthe separator 130 is a porous polymer membrane infused with a liquidelectrolyte that allows for the shuttling of ions between the semi-solidcathode 140 and the semi-solid anode 150 electroactive materials, whilepreventing the transfer of electrons. In some embodiments, the separator130 is a microporous membrane that prevents particles forming thepositive and negative electrode compositions from crossing the membrane.In some embodiments, the separator 130 is a single or multilayermicroporous separator, optionally with the ability to fuse or “shutdown” above a certain temperature so that it no longer transmits workingions, of the type used in the lithium ion battery industry andwell-known to those skilled in the art. In some embodiments, theseparator 130 can include a polyethyleneoxide (PEO) polymer in which alithium salt is complexed to provide lithium conductivity, or Nafion™membranes which are proton conductors. For example, PEO basedelectrolytes can be used as the separator 130, which is pinhole-free anda solid ionic conductor, optionally stabilized with other membranes suchas glass fiber separators as supporting layers. PEO can also be used asa slurry stabilizer, dispersant, etc. in the positive or negative redoxcompositions. PEO is stable in contact with typical alkylcarbonate-based electrolytes. This can be especially useful inphosphate-based cell chemistries with cell potential at the positiveelectrode that is less than about 3.6 V with respect to Li metal. Theoperating temperature of the redox cell can be elevated as necessary toimprove the ionic conductivity of the membrane.

The cathode 140 can be a semi-solid stationary cathode or a semi-solidflowable cathode, for example of the type used in redox flow cells(e.g., redox flow cells described in the '848 publication and the '226patent). The semi-solid cathode 140 can include an ion-storing solidphase material which can include, for example, an active material and/ora conductive material. The quantity of the ion-storing solid phasematerial can be in the range of about 0% to about 75% by volume. Thecathode 140 can include an active material such as, for example, alithium bearing compound (e.g., Lithium Iron Phosphate (LFP), LiCoO₂,LiCoO₂ doped with Mg, LiNiO₂, Li(Ni, Co, Al)O₂ (known as “NCA”), Li(Ni,Mn, Co)O₂ (known as “NMC”), LiMn₂O₄ and its derivatives, etc.). Thecathode 140 can also include a conductive material such as, for example,graphite, carbon powder, pyrolytic carbon, carbon black, carbon fibers,carbon microfibers, carbon nanotubes (CNTs), single walled CNTs, multiwalled CNTs, fullerene carbons including “bucky balls,” graphene sheetsand/or aggregate of graphene sheets, any other conductive material,alloys or combination thereof. The cathode 140 can also include anon-aqueous liquid electrolyte such as, for example, ethylene carbonate,dimethyl carbonate, diethyl carbonate, or any other electrolytedescribed herein or combination thereof.

In some embodiments, the anode 150 can be a semi-solid stationary anode.In some embodiments, the anode 150 can be a semi-solid flowable anode,for example, of the type used in redox flow cells (e.g., redox flowcells described in the '848 publication and the '226 patent).

In some embodiments, the semi-solid anode 150 can also include anion-storing solid phase material which can include, for example, anactive material and/or a conductive material. The quantity of theion-storing solid phase material can be in the range of about 0% toabout 80% by volume. In some embodiments, the quantity of theion-storing solid phase material can be in the range of about 0% toabout 75% by volume. The anode 150 can include an anode active materialsuch as, for example, lithium metal, carbon, lithium-intercalatedcarbon, lithium nitrides, lithium alloys and lithium alloy formingcompounds of silicon, bismuth, boron, gallium, indium, zinc, tin, tinoxide, antimony, aluminum, titanium oxide, molybdenum, germanium,manganese, niobium, vanadium, tantalum, gold, platinum, iron, copper,chromium, nickel, cobalt, zirconium, yttrium, molybdenum oxide,germanium oxide, silicon oxide, silicon carbide, any other materials oralloys thereof, and any other combination thereof.

The anode 150 (e.g., a semi-solid anode) can also include a conductivematerial which can be a carbonaceous material such as, for example,graphite, carbon powder, pyrolytic carbon, carbon black, carbon fibers,carbon microfibers, carbon nanotubes (CNTs), single walled CNTs, multiwalled CNTs, fullerene carbons including “bucky balls”, graphene sheetsand/or aggregate of graphene sheets, any other carbonaceous material orcombination thereof. In some embodiments, the anode 150 can also includea non-aqueous liquid electrolyte such as, for example, ethylenecarbonate, dimethyl carbonate, diethyl carbonate, or any otherelectrolyte described herein or combination thereof.

In some embodiments, the semi-solid cathode 140 and/or the semi-solidanode 150 can include active materials and optionally conductivematerials in particulate form suspended in a non-aqueous liquidelectrolyte. In some embodiments, the semi-solid cathode 140 and/or thesemi-solid anode 150 particles (e.g., cathodic or anodic particles) canhave an effective diameter of at least about 1 μm. In some embodiments,the cathodic or anodic particles can have an effective diameter betweenabout 1 μm and about 10 μm. In other embodiments, the cathodic or anodicparticles can have an effective diameter of at least about 10 μm ormore. In some embodiments, the cathodic or anodic particles can have aneffective diameter of less than about 1 μm. In other embodiments, thecathodic or anodic particles can have an effective diameter of less thanabout 0.5 μm. In other embodiments, the cathodic or anodic particles canhave an effective diameter of less than about 0.25 μm. In otherembodiments, the cathodic or anodic particles can have an effectivediameter of less than about 0.1 μm. In other embodiments, the cathodicor anodic particles can have an effective diameter of less than about0.05 μm. In other embodiments, the cathodic or anodic particles have aneffective diameter of less than about 0.01 μm.

In some embodiments, the semi-solid cathode 140 can include about 20% toabout 80% by volume of an active material. In some embodiments, thesemi-solid cathode 140 can include about 40% to about 75% by volume,about 50% to about 75% by volume, about 60% to about 75% by volume, orabout 60% to about 80% by volume of an active material. In someembodiments, the semi-solid cathode 140 can include about 20% to about75% by volume of an active material.

In some embodiments, the semi-solid cathode 140 can include about 0% toabout 25% by volume of a conductive material. In some embodiments, thesemi-solid cathode 140 can include about 1.0% to about 6% by volume,about 6% to about 12% or about 2% to about 15% by volume of a conductivematerial. In some embodiments, the semi-solid cathode 140 can includeabout 0.5% to about 20% by volume of a conductive material.

In some embodiments, the semi-solid cathode 140 can include about 20% toabout 70% by volume of an electrolyte. In some embodiments, thesemi-solid cathode 140 can include about 30% to about 60%, about 40% toabout 50%, or about 20% to about 40% by volume of an electrolyte.

In some embodiments, the semi-solid cathode 140 can include about 20% toabout 75% by volume of an active material, about 0.5% to about 20% byvolume of a conductive material, and about 20% to about 70% by volume ofan electrolyte.

In some embodiments, the semi-solid anode 150 can include about 20% toabout 80% by volume of an active material. In some embodiments, thesemi-solid anode 150 can include about 40% to about 75% by volume, about50% to about 75%, about 60% to about 75%, or about 60% to about 80% byvolume of an active material. In some embodiments, the semi-solid anode150 can include about 10% to about 75% by volume of an active material.

In some embodiments, the semi-solid anode 150 can include about 0% toabout 20% by volume of a conductive material. In some embodiments, thesemi-solid anode 150 can include about 1% to about 10%, 1% to about 6%,about 0.5% to about 2%, about 2% to about 6%, or about 2% to about 4% byvolume of a conductive material. In some embodiments, the semi-solidanode 150 can include about 0.5% to about 20% by volume of a conductivematerial.

In some embodiments, the semi-solid anode 150 can include about 20% toabout 70% by volume of an electrolyte. In some embodiments, thesemi-solid anode 150 can include about 30% to about 60%, about 40% toabout 50%, or about 20% to about 40% by volume of an electrolyte.

Examples of active materials, conductive materials, and/or electrolytesthat can be used in the semi-solid cathode 140 and/or the semi-solidanode 150 compositions, various formulations thereof, andelectrochemical cells formed therefrom, are described in the '524publication, the '848 publication, and the '226 patent.

In some embodiments, the semi-solid anode 150 can also include about 1%to about 30% by volume of a high capacity material. Such high capacitymaterials can include, for example, silicon, bismuth, boron, gallium,indium, zinc, tin, antimony, aluminum, titanium oxide, molybdenum,germanium, manganese, niobium, vanadium, tantalum, iron, copper, gold,platinum, chromium, nickel, cobalt, zirconium, yttrium, molybdenumoxide, germanium oxide, silicon oxide, silicon carbide, any other highcapacity materials or alloys thereof, and any combination thereof. Insome embodiments, the semi-solid anode can include about 1% to about 5%by volume, about 1% to about 10% by volume, about 1% to about 20%, orabout 1% to about 30% by volume of the high capacity material. Examplesof high capacity materials that can be included in the semi-solid anode150, various formulations thereof and electrochemical cells formedtherefrom, are described in the '606 application.

In some embodiments, the electrolyte included in at least one of thesemi-solid cathode 140 and the semi-solid anode 150 can include about0.01% to about 1.5% by weight of a polymer additive. In someembodiments, the electrolyte can include about 0.1% to about 1.25% byweight, about 0.1% to about 1% by weight of the polymer additive, about0.1% to about 0.7% by weight, about 0.1% to about 0.5% by weight, orabout 0.1% to about 0.3% by weight of the polymer additive. In someembodiments, the electrolyte can include about 0.01% to about 0.7% byweight, about 0.1% to about 0.7% by weight, about 0.3% to about 0.7% byweight, about 0.4% to about 0.6% by weight, about 0.45% to about 0.55%by weight, about 0.1% to about 0.5% by weight, about 0.3% to about 0.5%by weight, about 0.4% to about 0.5% by weight, about 0.1% to about 0.4%by weight, about 0.2% to about 0.4% by weight, about 0.1% to about 0.3%by weight, or about 0.1% to about 0.2% by weight of the polymeradditive.

Various polymer additives can be included in the semi-solid electrodecompositions described herein. In some embodiments, the polymer additivecan include a gel polymer additive, for example, a physically crosslinked gel polymer additive and/or a chemically cross linked gel polymeradditive. In some embodiments, the gel polymer additive can include, forexample, an acrylate or a methacrylate group including but not limitedto poly(ethyleneglycol dimethacrylate), poly(ethyleneglycol diacrylate),poly(propyleneglycol dimethacrylate), poly(propyleneglycol diacrylate),and poly(methyl methacrylate) (PMMA). In some embodiments, the gelpolymer additive can include the commercially available gel polymeradditives ACG Elexcel™ and ERM-1 Elexcel™.

In some embodiments, the polymer additive can include carboxy methylcellulose CMC, for example, a high molecular weight type CMC (e.g.,MAC800LC™ available from Nippon Paper Chemicals Co. Ltd.), a mediummolecular weight type CMC, or low molecular weight type CMC. Otherexamples of polymer additives can include poly(acrylonitrile) (PAN),polyurethane (PU), poly(vinylidene difluoride) (PVdF), poly(ethyleneoxide) (PEO), polypropylene oxide) poly(ethyleneglycol dimethylether),poly(ethyleneglycol diethylether), poly[bis(methoxyethoxyethoxide)-phosphazene], poly(dimethylsiloxane) (PDMS), polyvinylpyridine (PVP) and NIPPON SHOKUBAI® polymer. In some embodiments, thepolymer additive can include a PEO copolymer having the followingchemical formula:

which is available from Daiso Chemical Company (also referred to hereinas the “Daiso Polymer I”). In some embodiments, the polymer additive caninclude a PEO terpolymer having the following chemical formula:

which is also available from Daiso Chemical Company (also referred toherein as the “Daiso Polymer II”).

In some embodiments, the polymer additive can include an electronconductive polymer such as, for example, polyaniline or polyacetylenebased conductive polymers or poly(3,4-ethylenedioxythiophene) (PEDOT),polydisulfide, polythione, polypyrrole, polythiophene,poly(p-phenylene), poly(triphenylene), polyazulene, polyfluorene,polynaphtalene, polyanthracene, polyfuran, polycarbazole,tetrathiafulvalene-substituted polystyrene, polystyrene sulfonate,ferrocene-substituted polyethylene, carbazole-substituted polyethylene,polyoxyphenazine, polyacenes, or poly(heteroacenes).

In some embodiments, the polymer additive can include a single-iontransfer polymer (also known as “single ion conductor polymer” or “anionreceptive polymer”) such as, for example, a polysulfone or polyetherbased gel polymer additive. Examples of single ion transfer polymeradditives include, for example,poly[(4-styrenesulfonyl)(trifluoromethanesulfonyl)imide-co-methoxy-polyethyleneglycolacrylate](Li[PSTFSI-co-MPEGA]), sulfonated poly(phenylene oxide) (PPO),N,N-dimethylacryl amide (DMAAm), and lithium2-acrylamido-2-methyl-1-propane sulfonate (LiAMPS), Poly(lithium2-Acrylamido-2-Methylpropanesulfonic Acid-Co-Vinyl Triethoxysilane).

In some embodiments, the polymer additive can also include a li-ionredox polymer such as, for example, polyethyleneoxide(PEO)/poly(lithiumsorbate), PEO/poly(lithium muconate), PEO/[poly(lithium sorbat)+BF₃], orany other li-ion redox polymer or combination thereof.

In some embodiments, the polymer additive can be in the form of an oilor grease. In such embodiments, the polymer additive can include forexample, silicone oil, polytetrafluoroethylene (PTFE),perfluoropolyether (PFPE), chlorotrifluoroethylene (CTFE), methylphenylsilicone, methyhydrogen silicone, dimethyl silicone, methylphenylsilicone, cyclic-dimethyl silicone, CRC 2-26® lubricant, CONDUCTALUBE®,conductive grease, siloxane, or the likes.

In some embodiments, the polymer additive enables higher loading ofactive and/or conductive material in the semi-solid cathode 140 and/orthe semi-solid anode 150. For example, the polymer additive canfacilitate the creation of a more stable percolation network of theconductive material, for example, an activated carbon network, that canenable higher loadings, for example, up to 80% loading of the activeand/or conductive material. Therefore electrochemical batteries formedfrom the semi-solid electrodes described herein can have higher chargecapacity and energy density.

As described herein, the polymer additive is formulated to enhance therheological properties of the semi-solid cathode 140 and/or thesemi-solid anode 150 without impacting the electronic performance of thecathode 140 and/or the anode 150, and the electrochemical cell formedtherefrom. In some embodiments, polymer additive included in the cathode140 and/or the anode 150 is not cured. In some embodiments, the polymeradditive included in the cathode 140 and/or the anode 150 (e.g., a gelpolymer additive) is cured, for example, via UV cross-linking, heating,chemical cross-linking, or any other suitable curing method.

In some embodiments, the cathode 140 and/or anode 150 semi-solidsuspensions can initially be flowable, and can be caused to becomenon-flowable by “fixing”. In some embodiments, fixing can be performedby the action of photopolymerization. In some embodiments, fixing isperformed by action of electromagnetic radiation with wavelengths thatare transmitted by the unfilled positive and/or negative electroactivezones of the electrochemical cell 100 formed from a semi-solid cathodeand/or semi-solid anode. In some embodiments, the semi-solid suspensioncan be fixed by heating. In some embodiments, one or more additives areadded to the semi-solid suspensions to facilitate fixing.

In some embodiments, the injectable and flowable semi-solid cathode 140and/or semi-solid anode 150 is caused to become non-flowable by“plasticizing”. In some embodiments, the rheological properties of theinjectable and flowable semi-solid suspension are modified by theaddition of a thinner, a thickener, and/or a plasticizing agent. In someembodiments, these agents promote processability and help retaincompositional uniformity of the semi-solid under flowing conditions andpositive and negative electroactive zone filling operations. In someembodiments, one or more additives are added to the flowable semi-solidsuspension to adjust its flow properties to accommodate processingrequirements.

Systems employing negative and/or positive ion-storage materials thatare insoluble storage hosts for working ions, meaning that saidmaterials can take up or release the working ion while all otherconstituents of the materials remain substantially insoluble in theelectrolyte, are particularly advantageous as the electrolyte does notbecome contaminated with electrochemical composition products. Inaddition, systems employing negative and/or positive lithium ion-storagematerials are particularly advantageous when using non-aqueouselectrochemical compositions.

In some embodiments, the semi-solid ion-storing redox compositionsinclude materials proven to work in conventional lithium-ion batteries.In some embodiments, the positive semi-solid electroactive materialcontains lithium positive electroactive materials and the lithiumcations are shuttled between the negative electrode and positiveelectrode, intercalating into solid, host particles suspended in aliquid electrolyte.

In some embodiment, the cathode 140 can be a semi-solid cathode and theanode 150 can be a conventional anode for example, a solid anode formedfrom the calendering process as is commonly known in the arts. In someembodiments, the cathode 140 can be a semi-solid cathode and the anode150 can also be a semi-solid anode as described herein. In someembodiments, the cathode 140 and the anode 150 can both be semi-solidflowable electrodes, for example, for use in a redox flow cell examplesof which are described in the '848 publication and the '226 patent.

FIG. 2 illustrates a flow diagram showing a method 200 for preparing asemi-solid electrode, for example, the semi-solid cathode 140 and/or thesemi-solid anode 150 described herein with reference to FIG. 1. Themethod 200 includes combining a polymer additive with a non-aqueousliquid electrolyte to form a polymer-electrolyte mixture, at 202. Thepolymer additive can include any of the polymer additives describedherein. The electrolyte can include ethylene carbonate, dimethylcarbonate, diethyl carbonate, or any other electrolyte described hereinor combination thereof. The quantity of the polymer additive in thenon-aqueous electrolyte can be in the range of about 0.01% to about 1.5%by weight of the non-aqueous electrolyte, for example, about 0.1% ofabout 1% by weight, about 0.1% to about 0.7% by weight of thenon-aqueous electrolyte, or any other concentration range describedherein. The mixing of the polymer additive and the non-aqueouselectrolyte can be performed with continuous agitation, for example,constant stirring using a magnetic stirrer, a mechanical stirrer,constant vibrations on a shaker table, or any other suitable agitationmechanism. The mixing is performed until the polymer additive completelydissolves in the non-aqueous electrolyte such as, for example, a periodof 24 hours or any other suitable time period.

An active material is combined with the polymer-electrolyte mixture andmixed to form an intermediate material, at 204. The active material caninclude any of the active materials described herein in any suitableconcentration range as described herein. A conductive material is thencombined with the intermediate material and mixed to form a semi-solidelectrode material, at 206. Mixing the conductive material with theintermediate material after the active material and thepolymer-electrolyte mixture are mixed together to form the intermediatematerial, can enable the formation of stable percolation networks in thesemi-solid electrode material. Stable percolation networks can, forexample, enhance the conductivity of the semi-solid electrodes and yielda stable and more flowable semi-solid suspension. In some embodiments,no conductive material is added to the intermediate material, such thatmixing of the active material with the polymer-electrolyte mixtureyields the semi-solid electrode material.

The mixing of the semi-solid electrode material can be performed usingany suitable mixing equipment such as, for example, a high shearmixture, a planetary mixture, a centrifugal mixture, a sigma mixture, aCAM mixture and/or a roller mixture. The mixing time and mixing speedare controlled such that a predetermined specific energy, for example,in the range of about 90 J/g to about 120 J/g is imparted to thesemi-solid electrode material. The semi-solid electrode material can bemixed until a relatively stable suspension or slurry forms. Such astable suspension can have a mixing index of at least about 0.80. Insome embodiments, the slurry components can be mixed in a batch processusing a batch mixer such as, for example, any of the mixing equipmentdescribed herein maintaining a specific spatial and/or temporal orderingof the component addition as described herein. In some embodiments, theslurry components can be mixed in a continuous process (e.g., in anextruder), with a specific spatial and/or temporal ordering of componentaddition.

In some embodiments, the process conditions can be selected to produce aprepared slurry having an electronic conductivity of at least about 10⁻⁶S/cm, at least about 10⁻⁵ S/cm, at least about 10⁻⁴ S/cm, at least about10⁻³ S/cm, or at least about 10⁻² S/cm. In some embodiments, the processconditions can be selected to produce a prepared slurry having anapparent viscosity at room temperature of less than about 100,000 Pa-s,less than about 10,000 Pa-s, or less than about 1,000 Pa-s, all at anapparent shear rate of 1,000 s⁻¹. In some embodiments, the processconditions can be selected to produce a prepared slurry having two ormore properties as described herein. Examples of mixing equipment thatcan be used to form the semi-solid electrode suspensions describedherein, as well as various mixing parameters are described in the '319publication.

After the mixing is performed to form the semi-solid electrode materialthat has the desired electronic and mechanical properties as describedherein, the semi-solid electrode material is formed into an electrode,at 208. In some embodiments, the electrode can be a stationary or fixedelectrode, for example, the electrode can be calendar roll formed,stamped and/or pressed, subjected to vibrational settling, and/or cut indiscrete sections. In some embodiments, the electrode can be a flowablesemi-solid electrode for use in a redox flow cell (e.g., the redox flowcells described in the '753 and the '226 patent). Additionally, in someembodiments, unwanted portions of material can be removed (e.g., maskingand cleaning) and optionally recycled back into the slurry manufacturingprocess.

Optionally, the polymer additive mixed in with the electrode can becured, at 210. For example, the polymer additive can include a gelpolymer additive which can be cured. In some embodiments curing includesmaintaining the formed electrode at room temperature, for example, atabout 25 degrees Celsius, for at least about 24 hour, or at least about72 hours. In some embodiments, the gel polymer additive can be cured ata temperature of at least about 65 degrees Celsius for a period of atleast about 24 hours, for example, about 72 hours. The semi-solidelectrode that includes the polymer additive as formed by the methoddescribed herein can have better workability and/or flowability thansemi-solid electrodes that do not include the gel polymer additive. Forexample, the semi-solid electrodes described herein can have a lowerstiffness than semi-solid electrodes that do not include gel polymeradditive.

The following examples show the electronic performance and mechanicalproperties of various electrochemical cells that include the semi-solidelectrodes described herein. Each of the electrochemical cells describedin the following examples was tested for cycle life. Various electronicparameters of the electrochemical cells described in the followingexamples were measured as parameters of cycle life, including chargecapacity retention, energy efficiency, ASI and normalized chargecapacity at various charge/discharge rates. Furthermore, examples thatinclude polymer additive in the semi-solid cathode and/or the semi-solidanode formulation were also tested for stiffness as a parameter ofworkability or flowability of the semi-solid electrodes. These examplesare only for illustrative purposes and are not intended to limit thescope of the present disclosure.

Comparative Example 1

An electrochemical cell comparative example 1 (also referred to as“Comp. Ex. 1”) was prepared from a semi-solid cathode and a semi-solidanode. The semi solid cathode was prepared by mixing about 40% LFP byvolume, with about 2% Ketjen by volume and about 58% by volume of SSDEelectrolyte. The semi-solid anode was prepared by mixing about 35% PGPTby volume, with about 2% C45 by volume and about 63% by volume of SSDEelectrolyte. The semi-solid cathode and semi-solid anode slurries wereprepared using a batch mixer fitted with roller blades. Mixing wasperformed at about 100 rpm for about 4 minutes. Each of the semi-solidcathode and the semi-solid anode had a thickness of about 500 μm. Thecell was tested using a Maccor battery tester and was cycled over avoltage range of V=2-3.9 V performed at about 25 degrees Celsius. Asshown in FIG. 6 and FIG. 7, the Comp. Ex. 1 electrochemical cell has anormalized charge capacity of about 0.5 at a C/2 charge rate over 10charge cycles, and a normalized charge capacity of about 0.47 at a C/2discharge charge rate over 10 discharge cycles.

Comparative Example 2

An electrochemical cell comparative example 2 (also referred to as“Comp. Ex. 2”) was prepared from a semi-solid cathode and a semi-solidanode. The semi solid cathode was prepared by mixing about 40% LFP byvolume, with about 2% Ketjen by volume and about 58% by volume of SSDEelectrolyte. The electrolyte included about 5% by volume of the ACGElexcel™ gel polymer additive. The semi-solid anode was prepared bymixing about 35% PGPT400 by volume, with about 2% C45 by volume andabout 63% by volume of SSDE electrolyte. The anode electrolyte alsoincluded about 5% by volume of the ACG Elexcel™ gel polymer additive.The cathode slurry was prepared using a batch mixer fitted with rollerblades. Mixing was performed at about 100 rpm for about 4 minutes. Eachof the semi-solid cathode and the semi-solid anode had a thickness ofabout 500 μm. After the semi-solid cathode and the semi-solid anode wereformed, the gel polymer additive was cured at about 60 degrees Celsiusfor about 72 hours. The cell was tested using a Maccor battery testerand was cycled over a voltage range of V=2-3.9 V performed at about 25degrees Celsius. The Comp. Ex. 2 electrochemical cell formed from thesemi-solid electrodes that included about 5% by weight of theelectrolyte of the gel polymer additive lost its entire charge capacity(data not shown) and therefore no further electronic measurements wereconducted on the Comp. Ex. 2.

Comparative Example 3

An electrochemical cell comparative example 3 (also referred to as“Comp. Ex. 3”) was prepared from a semi-solid cathode and a semi-solidanode. The semi solid cathode was prepared by mixing about 40% LFP byvolume, with about 2% Ketjen by volume and about 58% by volume of SSDEelectrolyte. The electrolyte included about 3% by volume of the ACGElexcel™ gel polymer additive. The semi-solid anode was prepared bymixing about 35% PGPT400 by volume, with about 2% C45 by volume andabout 63% by volume of SSDE electrolyte. The anode electrolyte alsoincluded about 3% by volume of the ACG Elexcel™ gel polymer additive.The cathode slurry was prepared using a batch mixer fitted with rollerblades. Mixing was performed at about 100 rpm for about 4 minutes. Eachof the semi-solid cathode and the semi-solid anode had a thickness ofabout 500 μm. After the semi-solid cathode and the semi-solid anode wereformed, the gel polymer additive was cured at about 60 degrees Celsiusfor about 72 hours. The cell was tested using a Maccor battery testerand was cycled over a voltage range of V=2-3.9 V performed at about 25degrees Celsius. The Comp. Ex. 3 electrochemical cell formed from thesemi-solid electrodes that included about 3% by weight of theelectrolyte of the gel polymer additive lost its entire charge capacity(data not shown) and therefore no further electronic measurements wereconducted on the Comp. Ex. 3.

Example 1

An electrochemical cell example 1 (also referred to as “Ex. 1”) wasprepared from a semi-solid cathode and a semi-solid anode. The semisolid cathode was prepared by mixing about 40% LFP by volume, with about2% Ketjen by volume and about 58% by volume of SSDE electrolyte. Theelectrolyte includes about 1% by weight of the ACG Elexcel™ gel polymeradditive. The semi-solid anode was prepared by mixing about 35% PGPT byvolume, with about 2% C45 by volume and about 63% by volume of SSDEelectrolyte. The electrolyte included about 1% by weight of the ACGElexcel™ gel polymer additive. The cathode slurry was prepared using abatch mixer fitted with roller blades. Mixing was performed at about 100rpm for about 4 minutes. Each of the semi-solid cathode and thesemi-solid anode had a thickness of about 500 μm. The cell was testedusing a Maccor battery tester and was cycled over a voltage range ofV=2-3.9 V performed at about 25 degrees Celsius. As shown in FIG. 3 theEx. 1 electrochemical cell retained about 93% of its initial chargecapacity after 12 charge/discharge cycles. As shown in FIG. 4, the Ex. 1electrochemical cell retained about 84% of its energy efficiency after12 charge/discharge cycles. As shown in FIG. 5, the initial ASI of theEx. 1 electrochemical cell was about 95 ohm-cm². The ASI dropped toabout 80 ohm-cm² after the first charge/discharge cycle but rose againto about 91 ohm-cm² after 12 charge/discharge cycles. As shown in FIG. 6and FIG. 7, the Ex. 1 electrochemical cell had a normalized chargecapacity of about 0.24 at a C/2 charge rate over 10 charge cycles, and anormalized charge capacity of about 0.09 at a C/2 discharge rate over 10discharge cycles.

Stiffness of the each of the semi-solid cathode and the semi-solid anodeincluded in the Ex. 1 electrochemical cell were also tested as a measureof electrode workability and flowability. The stiffness was measuredafter mixing of the electrode and is shown in FIG. 8. The gel polymeradditive included in each of the semi-solid anode and the semi-solidcathode was cured at three different conditions; (1) in a freezer thathad a temperature of about +4 degrees Celsius for about 24 hours; (2) ina glove box at room temperature, i.e. about 25 degrees Celsius for about24 hours; and (3) at about 65 degrees Celsius for about 3 days (72hours). The stiffness of each of the semi-solid cathode and semi-solidanode included in the Ex. 1 electrochemical cell was also measured aftereach of the curing conditions and is shown in FIG. 9. As shown in FIG. 8and FIG. 9, the semi-solid cathode included in Ex. 1 had a stiffness ofabout 5,000 Pa after mixing, while the semi-solid anode had a stiffnessof about 700 Pa after mixing. The semi-solid cathode cured for 24 hoursin the freezer had a stiffness of about 7,000 Pa. The semi-solid cathodecured for 24 hours at room temperature had a stiffness of about 11,000Pa, while the semi-solid cathode cured for 72 hours at about 65 degreesCelsius had a stiffness of about 18,000 Pa. The semi-solid anode curedfor 24 hours in the freezer had a stiffness of about 700 Pa. Thesemi-solid anode cured for 24 hours at room temperature had a stiffnessof about 1,200 Pa, while the semi-solid anode cured for 72 hours atabout 65 degrees Celsius had a stiffness of about 2,300 Pa.

Example 2

An electrochemical cell example 2 (also referred to as “Ex. 2”) wasprepared from a semi-solid cathode and a semi-solid anode. The semisolid cathode was prepared by mixing about 40% LFP by volume, with about2% Ketjen by volume, and about 58% by volume of SSDE electrolyte. Theelectrolyte includes about 0.5% by weight of the ACG Elexcel™ gelpolymer additive. The semi-solid anode was prepared by mixing about 35%PGPT by volume, with about 2% C45 by volume and about 63% by volume ofSSDE electrolyte. The electrolyte included about 0.5% by weight of theACG Elexcel™ gel polymer additive. The cathode slurry was prepared usinga batch mixer fitted with roller blades. Mixing was performed at about100 rpm for about 4 minutes. Each of the semi-solid cathode and thesemi-solid anode had a thickness of about 500 μm. The cell was testedusing a Maccor battery tester and was cycled over a voltage range ofV=2-3.9 V performed at about 25 degrees Celsius. As shown in FIG. 3 theEx. 2 electrochemical cell retained about 98% of its initial chargecapacity after 12 charge/discharge cycles. As shown in FIG. 4, the Ex. 2electrochemical cell retained about 89% of its energy efficiency after12 charge/discharge cycles. As shown in FIG. 5, the initial ASI of theEx. 2 electrochemical cell was about 93 ohm-cm². The ASI dropped toabout 75 ohm-cm² after the first charge/discharge cycle and remained thesame even after 12 charge/discharge cycles. As shown in FIG. 6 and FIG.7, the Ex. 2 electrochemical cell had a normalized charge capacity ofabout 0.5 at a C/2 charge rate over 10 charge cycles, and a normalizedcharge capacity of also about 0.5 at a C/2 discharge rate over 10discharge cycles.

Example 3

An electrochemical cell example 3 (also referred to as “Ex. 3”) wasprepared from a semi-solid cathode and a semi-solid anode. The semisolid cathode was prepared by mixing about 40% LFP by volume, with about2% Ketjen by volume and about 58% by volume of SSDE electrolyte. Theelectrolyte includes about 0.1% by weight of the ACG Elexcel™ gelpolymer additive. The semi-solid anode was prepared by mixing about 35%PGPT by volume, with about 2% C45 by volume and about 63% by volume ofSSDE electrolyte. The electrolyte include about 0.1% by weight of theACG Elexcel™ gel polymer additive. The cathode slurry was prepared usinga batch mixer fitted with roller blades. Mixing was performed at about100 rpm for about 4 minutes. Each of the semi-solid cathode and thesemi-solid anode had a thickness of about 500 μm. The cell was testedusing a Maccor battery tester and was cycled over a voltage range ofV=2-3.9 V performed at about 25 degrees Celsius. As shown in FIG. 3 theEx. 3 electrochemical cell retained about 98% of its initial chargecapacity after 12 charge/discharge cycles. As shown in FIG. 4, the Ex. 3electrochemical cell retained about 89% of its energy efficiency after12 charge/discharge cycles. As shown in FIG. 5, the initial ASI of theEx. 3 electrochemical cell was about 92 ohm-cm². The ASI dropped toabout 75 ohm-cm² after the first charge/discharge cycle and remained atabout 75 ohm-cm² after 12 charge/discharge cycles. As shown in FIG. 6and FIG. 7, the Ex. 3 electrochemical cell had a normalized chargecapacity of about 0.5 at a C/2 charge rate over 10 charge cycles, and anormalized charge capacity of also about 0.5 at a C/2 discharge rateover 10 discharge cycles.

Stiffness of the each of the semi-solid cathode and the semi-solid anodeincluded in the Ex. 5 electrochemical cell were also tested as a measureof electrode workability and flowability. The stiffness was measuredafter mixing of the electrode and is shown in FIG. 8. The gel polymeradditive included in each of the semi-solid anode and the semi-solidcathode was then cured at three different conditions; (1) in a freezerthat had a temperature of about +4 degrees Celsius for about 24 hours;(2) In a glove box at room temperature, i.e. about 25 degrees Celsiusfor about 24 hours and (3) at about 65 degrees Celsius for about 3 days(72 hours). The stiffness of each of the semi-solid cathode andsemi-solid anode included in the Ex. 3 electrochemical cell was alsomeasured after each of the curing conditions and is shown in FIG. 9. Asshown in FIG. 8 and FIG. 9, the semi-solid cathode included in Ex. 3 hada stiffness of about 7,000 Pa after mixing, while the semi-solid anodehad a stiffness of about 950 Pa after mixing. The semi-solid cathodecured for 24 hours in the freezer had a stiffness of about 7,000 Pa. Thesemi-solid cathode cured for 24 hours at room temperature had astiffness of about 10,500 Pa, while the semi-solid cathode cured for 72hours at about 65 degrees Celsius had a stiffness of about 14,500 Pa.The semi-solid anode cured for 24 hours in the freezer had a stiffnessof about 900 Pa. The semi-solid anode cured for 24 hours at roomtemperature had a stiffness of about 1,250 Pa, while the semi-solidcathode cured for 72 hours at about 65 degrees Celsius had a stiffnessof about 1,850 Pa.

The electronic performance parameters of each of the comparativeexamples, Ex. 1, Ex. 2 and Ex. 3 are summarized in Table 1.

TABLE 1 Quantity Charge Energy Normalized Normalized of Gel RetentionEfficiency Charge Discharge Polymer after 12 after 12 ASI after Capacityat Capacity at Additive cycles cycles 12 cycles C/2 Rate after C/2 Rateafter (wt %) (%) (%) Ω-cm² 10 cycles 10 cycles Comp. Ex. 1 0 — — — 0.50.47 Comp. Ex. 2 5 — — — — — Comp. Ex. 3 3 — — — — — Ex. 1 1 93 84 910.24 0.09 Ex. 2 0.5 98 89 75 0.5 0.5 Ex. 2 0.1 98 89 75 0.5 0.5

The stiffness of the semi-solid cathode and the semi-solid anodeincluded in each of comparative examples, Ex. 1, Ex. 2, and Ex. 3electrochemical cells are summarized in Table 2.

TABLE 2 Quantity of Stiffness Semi- Gel Polymer After 24 Hours 24 Hoursat 72 Hours at Solid Additive Mixing in Freezer Room Temp. 65 Degrees C.Electrode (wt %) Pa Pa Pa Pa Comp. Cathode 0 — — — — Ex. 1 Anode 0 — — —— Comp. Cathode 5 — — — Ex. 2 Anode 5 — — — — Comp. Cathode 3 5,0007,000 — — Ex. 3 Anode 3 650 700 Ex. 1 Cathode 1 5,000 7,000 11,00018,000 Anode 1 700 700 1,200 2,300 Ex. 2 Cathode 0.5 — — — — Anode 0.5 —— — — Ex. 3 Cathode 0.1 7,000 7,000 10,500 14,500 Anode 0.1 950 9001,250 1,850

Ex. 1 electrochemical cell retains a substantial amount of chargecapacity and energy efficiency after 10 cycles but the cell impedancestarts to increase. A significant reduction in the normalized charge anddischarge capacity after 10 cycles was also observed. In contrast, theEx. 2 electrochemical cell and Ex. 3 electrochemical cell retain ahigher percentage of charge capacity and energy efficiencies incomparison to the Ex. 1 electrochemical cell. Ex. 2 and Ex. 3 alsodemonstrate a higher charge capacity and discharge capacity at theC/2-rate. Furthermore, the semi-solid cathode and semi-solid anodeincluded in Ex. 3 have a lower stiffness than the semi-solid electrodesof Ex. 1 when cured at the 65 degrees Celsius for 72 hours, implyingthat the Ex. 3 semi-solid electrodes cured under these conditions can bemore workable and more amenable to flow.

Electronic Performance of Electrochemical Cells Including Anodes thatInclude a Polymer Additive

Various semi-solid anode formulations were prepared that included anuncured polymer additive and their electronic performance was comparedto the electronic performance of a control anode that did not includethe polymer additive.

A control semi-solid anode (also referred to as the “Control Anode”) wasprepared by mixing about 55% by volume of meso carbon microbeads (MGPA®)as the active material with about 1% by volume of C45 conductivematerial in an electrolyte. The electrolyte was formulated to includeethylene carbonate/gamma-butyrolactone in a ratio of 30:70, 1.1 M ofLiBF₄ salt, about 2% by volume of vinylene carbonate and about 0.5% byvolume of trioctyl phosphate The Control Anode slurry was prepared bymixing the components at about 650 rpm for about 6 minutes. The ControlAnode had a thickness of about 300 μm.

A first semi-solid anode (also referred to as the “CMC Anode) wasprepared substantially similar to the Control Anode, but now theelectrolyte included about 1.5% by weight of a carboxymethyl cellulose(MAC800LCT™ from Nippon Paper Chemicals Co. Ltd) polymer additive. Thethickness of the CMC Anode was also about 300 μm.

A second semi-solid anode (also referred to as the “Daiso Anode) wasprepared substantially similar to the Control Anode, but now theelectrolyte included about 1.5% by weight of the DAISO polymer additive,as described before herein. The thickness of the Daiso Anode was alsoabout 300 μm.

A third semi-solid anode (also referred to as the “Nippon Anode) wasprepared substantially similar to the Control Anode, but now theelectrolyte included about 1.5% by weight of a NIPPON SHOKUBAI® polymeradditive. The thickness of the Nippon Anode was also about 300 μm.

Each of the semi-solid anodes were paired against a semi-solid cathodeto form an electrochemical cell. The semi-solid cathode was formed bymixing about 50% by volume of LFP with about 0.8% by volume of Ketjenand an electrolyte. The electrolyte was formulated to include ethylenecarbonate/gamma-butyrolactone in a ratio of 30:30, 1.1 M of LiBF₄ salt,about 2% by volume of vinylene carbonate and about 0.5% by volume oftrioctyl phosphate. The semi-solid cathode slurry was prepared by mixingthe components in a speed mixer at about 1250 rpm for about 90 seconds.The thickness of the cathode was about 300 μm.

Each of the electrochemical cells that include the semi-solid anodes andthe semi-solid cathode were tested for two cycles at a C-rate of aboutC/10 and then for 10 cycles at a C-rate of C/4. FIG. 10 shows thevoltage vs capacity profiles for the C/10 cycles, while FIG. 11 showsthe voltage vs capacity profiles for the C/4 cycles. As shown, thevoltage vs capacity profiles for each of the Control Anode, the CMCAnode, the Daiso Anode, and the Nippon Anode were substantially the samefor each of the C/10 cycles as well as the C/4 cycles.

Next, the capacity retention of each of the electrochemical cell afterfive charge/discharge cycles was measured. As shown in FIG. 12, theelectrochemical cell that includes the Control Anode and theelectrochemical cell that includes the CMC anode retain almost 99% ofits initial capacity after 5 cycles. The electrochemical cell thatincludes the Daiso Anode retained about 97.5% of its initial capacity,while the Nippon Anode retained about 96% if it's initial capacity after5 cycles.

While various embodiments of the system, methods and devices have beendescribed above, it should be understood that they have been presentedby way of example only, and not limitation. Where methods and stepsdescribed above indicate certain events occurring in certain order,those of ordinary skill in the art having the benefit of this disclosurewould recognize that the ordering of certain steps may be modified andsuch modification are in accordance with the variations of theinvention. For example, the curing of the gel polymer additive can alsobe used to fix the semi-solid cathode and/or semi-solid anode.Additionally, certain of the steps may be performed concurrently in aparallel process when possible, as well as performed sequentially asdescribed above. The embodiments have been particularly shown anddescribed, but it will be understood that various changes in form anddetails may be made.

The invention claimed is:
 1. A semi-solid electrode, comprising: about20% to about 75% by volume of an active material; about 0.5% to about25% by volume of a conductive material; and about 20% to about 70% byvolume of an electrolyte, the electrolyte including about 0.01% to 1.5%by weight of a polymer additive, wherein a total polymer content in theelectrolyte is less than or equal to 1.5% by weight, and wherein thesemi-solid electrode is a mixture of the active material, the conductivematerial and the electrolyte with the polymer additive.
 2. Thesemi-solid electrode of claim 1, wherein the electrolyte includes about0.1% to about 1.25% by weight of the polymer additive.
 3. The semi-solidelectrode of claim 2, wherein the electrolyte includes about 0.1% toabout 1% by weight of the polymer additive.
 4. The semi-solid electrodeof claim 3, wherein the electrolyte includes about 0.1% to about 0.7% byweight of the polymer additive.
 5. The semi-solid electrode of claim 4,wherein the electrolyte includes about 0.1% to about 0.5% by weight ofthe polymer additive.
 6. The semi-solid electrode of claim 5, whereinthe electrolyte includes about 0.1% to about 0.3% by weight of thepolymer additive.
 7. The semi-solid electrode of claim 1, wherein thepolymer additive is a gel-polymer additive.
 8. The semi-solid electrodeof claim 7, wherein the gel polymer additive includes at least one of aphysically cross-linked gel polymer additive and a chemicallycross-linked gel polymer additive.
 9. The semi-solid electrode of claim7, wherein the gel polymer additive includes at least one of an acrylategroup and a methacrylate group.
 10. The semi-solid electrode of claim 1,wherein the polymer additive is carboxy methyl cellulose.
 11. Thesemi-solid electrode of claim 1, wherein the polymer additive includesat least one of a poly(ethyleneglycol dimethacrylate),poly(ethyleneglycol diacrylate), poly(propyleneglycol dimethacrylate),poly(propyleneglycol diacrylate), and poly(methyl methacrylate) (PMMA),polyethylene glycol dimethacrylate, poly(acrylonitrile) (PAN),polyurethane (PU), poly(vinylidene difluoride) (PVdF), poly(ethyleneoxide) (PEO), poly(propylene oxide) poly(ethyleneglycol dimethylether),poly(ethyleneglycol diethylether), poly[bis(methoxyethoxyethoxide)-phosphazene], poly(dimethylsiloxane) (PDMS), polyacene,polydisulfide, polystyrene, polystyrene sulfonate, polypyrrole,polyaniline, polythiophene, polythione, polyvinyl pyridine (PVP),polyvinyl chloride (PVC), polyaniline, poly(3,4-ethylenedioxythiophene)(PEDOT), polypyrrole, polythiophene, poly(p-phenylene),poly(triphenylene), polyazulene, polyfluorene, polynaphtalene,polyanthracene, polyfuran, polycarbazole, tetrathiafulvalene-substitutedpolystyrene, ferrocene-substituted polyethylene, carbazole-substitutedpolyethylene, polyoxyphena zine, poly(heteroacene),poly[(4-styrenesulfonyl)(trifluoromethanesulfonyl)imide-co-methoxy-polyethyleneglycolacrylate](Li[PSTFSI-co-MPEGA]), sulfonated poly(phenylene oxide) (PPO),N,N-dimethylacryl amide (DMAAm), and lithium2-acrylamido-2-methyl-1-propane sulfonate (LiAMPS), Poly(lithium2-Acrylamido-2-Methylpropanesulfonic Acid-Co-Vinyl Triethoxysilane),polyethyleneoxide(PEO)/poly(lithium sorbate), PEO/poly(lithiummuconate), PEO/[poly(lithium sorbat)+BF₃], PEO copolymer, and PEOterpolymer poly.
 12. A semi-solid electrode, comprising: about 10% toabout 75% by volume of an active material; about 0.5% to about 20% byvolume of a conductive material; and about 20% to about 70% by volume ofan electrolyte, the electrolyte including about 0.01% to 1.5% by weightof a polymer additive, wherein a total polymer content in theelectrolyte is less than or equal to 1.5% by weight, and wherein thesemi-solid electrode is a mixture of the active material, the conductivematerial and the electrolyte with the polymer additive.
 13. Thesemi-solid electrode of claim 12, wherein the semi-solid electrodefurther includes about 1% to about 30% by volume of a high capacitymaterial.
 14. The semi-solid electrode of claim 12, wherein theelectrolyte includes about 0.1% to about 1% by weight of the polymeradditive.
 15. The semi-solid electrode of claim 12, wherein the polymeradditive includes at least one of a poly(ethyleneglycol dimethacrylate),poly(ethyleneglycol diacrylate), poly(propyleneglycol dimethacrylate),poly(propyleneglycol diacrylate), and poly(methyl methacrylate) (PMMA),polyethylene glycol dimethacrylate, poly(acrylonitrile) (PAN),polyurethane (PU), poly(vinylidene difluoride) (PVdF), poly(ethyleneoxide) (PEO), poly(propylene oxide) poly(ethyleneglycol dimethylether),poly(ethyleneglycol diethylether), poly[bis(methoxyethoxyethoxide)-phosphazene], poly(dimethylsiloxane) (PDMS), polyacene,polydisulfide, polystyrene, polystyrene sulfonate, polypyrrole,polyaniline, polythiophene, polythione, polyvinyl pyridine (PVP),polyvinyl chloride (PVC), polyaniline, poly(3,4-ethylenedioxythiophene)(PEDOT), polypyrrole, polythiophene, poly(p-phenylene),poly(triphenylene), polyazulene, polyfluorene, polynaphtalene,polyanthracene, polyfuran, polycarbazole, tetrathiafulvalene-substitutedpolystyrene, ferrocene-substituted polyethylene, carbazole-substitutedpolyethylene, polyoxyphena zine, poly(heteroacene),poly[(4-styrenesulfonyl)(trifluoromethanesulfonyl)imide-co-methoxy-polyethyleneglycolacrylate](Li[PSTFSI-co-MPEGA]), sulfonated poly(phenylene oxide) (PPO),N,N-dimethylacryl amide (DMAAm), and lithium2-acrylamido-2-methyl-I-propane sulfonate (LiAMPS), Poly(lithium2-Acrylamido-2-Methylpropanesulfonic Acid-Co-Vinyl Triethoxysilane),polyethyleneoxide(PEO)/poly(lithium sorbate), PEO/poly(lithiummuconate), PEO/[poly(lithium sorbat)+BF₃], PEO copolymer, and PEOterpolymer poly.
 16. The semi-solid electrode of claim 12, wherein thepolymer additive is a gel-polymer additive.
 17. A semi-solid electrode,comprising: an active material; a conductive material; and about 20% toabout 70% by volume of an electrolyte, the electrolyte including about0.01% to 1.5% by weight of a gel-polymer additive, wherein a totalpolymer content in the electrolyte is less than or equal to 1.5% byweight, and wherein the semi-solid electrode is a mixture of the activematerial, the conductive material and the electrolyte with the polymeradditive.
 18. The semi-solid electrode of claim 17, wherein thesemi-solid electrode further includes about 1% to about 30% by volume ofa high capacity material.
 19. The semi-solid electrode of claim 17,wherein the electrolyte includes about 0.1% to about 1% by weight of thegel-polymer additive.
 20. The semi-solid electrode of claim 17, whereinthe polymer additive includes at least one of a poly(ethyleneglycoldimethacrylate), poly(ethyleneglycol diacrylate), poly(propyleneglycoldimethacrylate), poly(propyleneglycol diacrylate), and poly(methylmethacrylate) (PMMA), polyethylene glycol dimethacrylate,poly(acrylonitrile) (PAN), polyurethane (PU), poly(vinylidenedifluoride) (PVdF), poly(ethylene oxide) (PEO), poly(propylene oxide)poly(ethyleneglycol dimethylether), poly(ethyleneglycol diethylether),poly[bis(methoxy ethoxyethoxide)-phosphazene], poly(dimethylsiloxane)(PDMS), polyacene, polydisulfide, polystyrene, polystyrene sulfonate,polypyrrole, polyaniline, polythiophene, polythione, polyvinyl pyridine(PVP), polyvinyl chloride (PVC), polyaniline,poly(3,4-ethylenedioxythiophene) (PEDOT), polypyrrole, polythiophene,poly(p-phenylene), poly(triphenylene), polyazulene, polyfluorene,polynaphtalene, polyanthracene, polyfuran, polycarbazole,tetrathiafulvalene-substituted polystyrene, ferrocene-substitutedpolyethylene, carbazole-substituted polyethylene, polyoxyphena zine,poly(heteroacene),poly[(4-styrenesulfonyl)(trifluoromethanesulfonyl)imide-co-methoxy-polyethyleneglycolacrylate](Li[PSTFSI-co-MPEGA]), sulfonated poly(phenylene oxide) (PPO),N,N-dimethylacryl amide (DMAAm), and lithium2-acrylamido-2-methyl-1-propane sulfonate (LiAMPS), Poly(lithium2-Acrylamido-2-Methylpropanesulfonic Acid-Co-Vinyl Triethoxysilane),polyethyleneoxide(PEO)/poly(lithium sorbate), PEO/poly(lithiummuconate), PEO/[poly(lithium sorbat)+BF₃], PEO copolymer, and PEOterpolymer poly.
 21. The semi-solid electrode of claim 17, wherein thesemi-solid electrode is cured for at least 24 hours.
 22. The semi-solidelectrode of claim 21, wherein the semi-solid electrode is cured at 65degrees Celsius.